Caja de Cambios Outlander

Section02 ENGINE, CVT AND GEARBOXSubsection 12 (GEARBOX AND 4X4 COUPLING UNIT)

GEARBOX AND 4X4 COUPLING UNITSERVICE TOOLSDescription Part Number Page

BLIND HOLE BEARING PULLER SET........................................... 529 036 117 ......................................... 199COUNTERSHAFT OIL SEAL PUSHER .......................................... 529 036 222 ......................................... 192ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 188FLUKE 115 MULTIMETER ............................................................ 529 035 868 ................................. 186, 190HANDLE ........................................................................................ 420 877 650 ......................................... 192OIL SEAL INSTALLER (GEARBOX) ............................................... 529 035 758 ......................................... 192OIL SEAL INSTALLER ................................................................... 529 036 204 ......................................... 193

SERVICE TOOLS OTHER SUPPLIERDescription Part Number Page

BACK PROBE TEST WIRES .......................................................... 529 036 063 ................................. 186, 188

SERVICE PRODUCTSDescription Part Number Page

LOCTITE 5910 ............................................................................... 293 800 081 ................................. 189, 205LOCTITE CHISEL (GASKET REMOVER) ....................................... 413 708 500 ......................................... 205SUPER LUBE GREASE.................................................................. 293 550 030 .........................187, 190, 193

tmr2013-020 183


GEARBOX COMPONENTS AND 4X4 COUPLING MECHANISM

?"?#$"$

?"3?3#$"

?.=" ?.#$"

?!"?#$"$

?"3?3#$"

?"3?3#$"

?!"?#$"$

=?.


GENERAL

GEARBOX OVERVIEW

Tmr2011-016-003_a

1. Gearbox position sensor (GBPS)2. Right cover3. Vehicle speed sensor (VSS)4. Actuator5. 4WD indicator switch

Tmr2011-016-004_a

1. Center housing2. Left cover3. Countershaft4. Output shaft5. Shift shaft

TROUBLESHOOTINGUNUSUAL GEARBOX NOISE AND/ORVIBRATIONS

1. Low oil level in gearbox.- Oil leakage from gearbox. Replace damaged gas-ket(s) and/or oil seal(s).

2. Defective bearings.- Bearing(s) do(es) not turn smoothly. Replacebearing(s).

3. Damaged or worn gears.- Inspect gears for damages or missing teeth. Re-place respective gears.

GEAR INDICATION FAILS

1. Defective gearbox position sensor (GBPS).- Perform a gearbox position sensor test.- Damaged wires. Repair as required.

GEAR(S) IS (ARE) HARD TO SHIFT

1. Incorrect shifter cable adjustment.- Adjust shifter cable (refer to SHIFTER CABLE inSHIFTER subsection.

4 WHEEL DRIVE INDICATION FAILS

1. 4WD indicator switch failure.- Test 4WD indicator switch. Replace as required.- Bad contact. Check for corrosion or loose con-nector.

- Damaged wires. Repair as required.

4 WHEEL DRIVE DOES NOT ENGAGE ORDISENGAGE

1. Defective 4WD switch.- Check 4WD switch operation.

2. Defective actuator.- Test actuator.

3. Damaged or worn shifting fork or sleeve.- Remove actuator and inspect shifting fork andsleeve.

PROCEDURES

VSS (VEHICLE SPEED SENSOR)VSS LocationThe vehicle speed sensor is located on the righthousing of the gearbox behind the actuator.

tmr2013-020 185


Tmr2011-016-006_a

1. Right housing of gearbox2. Actuator3. VSS (Vehicle Speed Sensor)

VSS AccessTo reach the VSS, remove the following parts: Passenger seat RH lateral console panel Fuel tank cowl.

VSS Wire IdentificationFUNCTION PIN COLOR

12-volt input from fuse F5 A RED

Speed signal(to ECM-A E1) B WHITE

Ground (to ECM-A D4) C BLACK/GREEN

VSS Circuit ProtectionCONDITION CIRCUIT PROTECTION

Supplied with mainrelay activated

Fuse 5 of fuse block 1(from main relay R2)

VSS Input Voltage Test1. Turn ignition switch ON.2. Back-probe the VSS connector and measure

voltage.

REQUIRED TOOLS

BACK PROBE TEST WIRES(P/N 529 036 063)

FLUKE 115 MULTIMETER(P/N 529 035 868)

VSS INPUT VOLTAGE TEST

TEST PROBES RESULT(KEY ON)

PIN A(RED wire)

PIN C(BLACK/GREEN

wire)Battery voltage

If voltage is not as specified, test positive andground separately.

VSS Signal Test1. Lift rear of vehicle so that rear wheels are off

the ground.2. Set transmission to 2WD and to Neutral.3. Turn ignition switch ON.4. Back-probe the VSS connector and measure

voltage while slowly rotating rear wheels byhand.

REQUIRED TOOLS



VSS SIGNAL TEST

TEST PROBESRESULT

(WHILE ROTATINGWHEELS)

PIN B(WHITEwire)

PIN C(BLACK/GREEN

wire)

Alternate readingbetween batteryvoltage and 0 Vdc

NOTE: Since we measure pulsating voltage, thenumeric display will continuously change. Theanalog display may be easier to follow.

smr2005-056-010_a

1. Analog display

186 tmr2013-020


VSS RemovalRemove screw retaining the VSS.

Tmr2011-016-088_a

1. Screw2. VSS

Turn sensor and weave it out of the gearbox rightcover.

tmr2011-016-089_a

VSS InstallationFor installation, reverse the removal procedure.Pay attention to the following.Apply SUPER LUBE GREASE (P/N 293 550 030) onVSS O-ring.

GBPS (GEARBOX POSITIONSENSOR)GBPS ResetWhen replacing the gearbox position sensor(GBPS), it is required to reset (re-zero) its valuesfor proper operation.A reset must be carried out each time any of thefollowing parts has been replaced: Gearbox assembly

Shift drum GBPS ECM.1. Connect vehicle to the latest applicable version

of B.U.D.S. software, refer to COMMUNICA-TION TOOLS AND B.U.D.S. subsection.

NOTE: Ignition key must stay ON during the resetprocedure. If the key is turned off, the proceduremust be carried out again.2. In B.U.D.S., select the following:

Read Data button Setting page tab ECM tab.

tmr2011-016-090_a

1. Read data button2. Setting page tab3. ECM tab

3. Make sure that gearbox is set to NEUTRAL po-sition.

4. In the Gear Position Sensor Initialization field,click on the Reset button.

tmr2011-016-091_a

GEAR POSITION SENSOR INITIALIZATION1. Reset button

A message will be displayed if the operation issuccessful.

tmr2013-020 187


If an error occurred or the GBPS is not within theallowed range while resetting, the ECM will gen-erate a fault code and will not accept the setting.5. If a fault message is displayed, follow the in-

structions in the message(s).6. Check for fault codes.If a fault code is generated: Carry out the service action. Reset the fault code. Repeat the reset procedure.7. Close and disconnect B.U.D.S.NOTE: Do not turn ignition key OFF.8. Verify gears engagement.

8.1 With the vehicle on ground and in NEU-TRAL position, start engine.

8.2 During 4-5 seconds, rev engine to 2500 200 RPM.

8.3 Let engine returns to idle.8.4 Select an other position (P, R, H or L). Re-

peat substeps 8.2 and 8.3 until all positionare verified.

NOTE: The vehicle must be in movement tocomplete the procedure on R, H and L posi-tion.

GBPS AccessTo reach the GBPS sensor, remove the followingparts: Passenger seat RH lateral console panel Fuel tank cowl.

GBPS Input Voltage TestNOTE: Prior to conduct testing, check fault codesin B.U.D.S.Set shift lever in NEUTRAL position.Back-probe the GBPS connector.

REQUIRED TOOL


Test as follow:

MULTIMETER PROBEPOSITIONS VOLTAGE

PIN 1 and PIN 3 of theGBPS connector

5 volts

If voltage is adequate, check GBPS communica-tion link (CAN).If there is no voltage, check each GBPS input asfollows.

MULTIMETER PROBEPOSITIONS VOLTAGE

GBPS connector (pin 1) andbattery ground

5 volts

GBPS connector (pin 3) andbattery + terminal

Battery voltage

If there is no voltage, check wires and connectorpins. Replace or repair defective parts and resetfault codes.

GBPS Communication Link ContinuityTestUnplug connector A from ECM and connect itto the ECM ADAPTER TOOL (P/N 529 036 166).

MULTIMETER PROBEPOSITIONS

RESISTANCE @20C (68F)

GBPS connector (pin 2) andECM adapter tool (pin F4)

Below 1

188 tmr2013-020


If resistance is out of specification, check wiresand connectors. Repair and reset fault codes.If resistance is good and the other tests suc-ceeded, replace the GBPS and reset fault codes.NOTE: The GBPS must be reset.

GBPS RemovalSet shift lever in NEUTRAL position.Unplug GBPS connector.Remove screws and withdraw GBPS.

Tmr2011-016-010_a

1. Screws2. Gearbox Position Sensor (GBPS)

GBPS InstallationFor installation, reverse the removal procedure.Pay attention to the following details.Shift lever must be in the NEUTRAL position.Align GBPS with the flat on the shift drum shaft.

Tmr2011-016-011_a

1. Flat on shift drum shaft

Reset the GBPS. Refer to GBPS RESET in thissubsection.

4WD INDICATOR SWITCH4WD Indicator Switch AccessTo reach the 4WD indicator switch, remove thefollowing parts: Passenger seat RH lateral console panel Fuel tank cowl.

4WD Indicator Switch RemovalDisconnect 4WD indicator switch connector.

Tmr2011-016-012_a

1. 4 WD indicator switch2. Actuator

4WD Indicator Switch TestMeasure switch resistance as follows.

SWITCHPOSITION SWITCH WIRE RESISTANCE

2WD BLACK/BEIGEEngineground Infinite (OL)

If the resistance is out of specification, replace the4WD indicator switch.

4WD Indicator Switch InstallationFor installation, reverse the removal procedure.Pay attention to the following details.Take care do not damage indicator switch threadsduring installation.Apply carefully some LOCTITE 5910 (P/N 293 800081) on threads of indicator switch.

NOTICE Do not apply Loctite 5910 on switchplunger, as it will lead to switch malfunction.

tmr2013-020 189


ACTUATORActuator AccessTo access the actuator, remove the followingparts: Passenger seat RH lateral console panel Fuel tank cowl.Remove screws securing fuel tank and move tankon passenger's floor without disconnecting hosesand connector from fuel pump.

Actuator TestCheck if the 2WD/4WD selector works properly.Unplug actuator connector.Turn ignition key ON.Measure voltage as follows.

REQUIRED TOOL


SWITCHPOSITION SWITCH WIRE VOLTAGE

2WD WHITE/BLUE

4WD WHITE/BLACKWHITE Batteryvoltage

If the selector is out of specifications, checkwires, connectors and replace the selector if nec-essary.If the selector is good, check the vehicle harness.If the vehicle harness is good, replace the actua-tor.

Actuator RemovalNOTE: Before beginning any servicing on the ac-tuator, make sure the vehicle is in 4WD position.No need to remove engine from vehicle.Place a drain pan under actuator.Remove actuator screws.

Tmr2011-016-025_a

1. Actuator2. Washer3. Screw

Pull the actuator out of housing.

Actuator InstallationApply a small amount of SUPER LUBE GREASE(P/N 293 550 030) on actuator O-ring.

vmr2006-035-002_A

1. Actuator O-ring

Ensure coupling fork is in 4WD position (towardthe front of vehicle).

190 tmr2013-020


Tmr2011-016-026_a

1. Coupling fork in 4WD position

Align the actuator fork with the pin on couplingfork then push the actuator in the housing. Seethe following illustration to position the actuatorcorrectly.

Tmr2011-016-027_a

1. Actuator2. Actuator fork3. Coupling fork

Rotate the actuator counterclockwise until it ori-ents itself to mounting position.

NOTICE Do not cut or break the actuatorO-ring.

Install all actuator screws and tighten them.

ACTUATOR SCREWS

Tightening torque 25Nm 3Nm(18 lbfft 2 lbfft)

Connect actuator.Lift the front of vehicle.Turn front wheels. The front propeller shaftshould not turn (the PARK position must be se-lected).

If the front propeller shaft turns, the actuator is notinstalled correctly. Remove actuator and reinstallit.Place ignition switch to ON position and select the2WD position.Turn front wheel again. The front propeller shaftshould turn easily.If the front propeller shaft does not turn, the ac-tuator is not installed correctly. Remove actuatorand reinstall it.

NOTICE Refill missing gearbox oil, refer toGEARBOX OIL REPLACEMENT in PERIODICMAINTENANCE PROCEDURES subsection.

Install all other removed parts.

GEARBOX OIL SEALSGearbox Oil Seal ReplacementReplace oil seals if they are brittle, hard or dam-aged.A small flat screwdriver can be used to removemost of these oil seals.

NOTICE Avoid scoring parts during oil sealremoval.

When replacing an oil seal, take this opportunityto inspect the following: Check bearings behind each oil seal for contam-ination and/or metal shavings.

Check oil seal running surfaces for scratches.

Countershaft Oil SealTo replace the countershaft oil seal, remove: Drive and driven pulleys CVT air guide.NOTE: When oil seal is removed also inspectO-ring behind distance sleeve.

Tmr2011-016-013_a

1. Countershaft oil seal2. Distance sleeve

tmr2013-020 191


Tmr2011-016-014_a

1. Distance sleeve2. O-ring

Install countershaft oil seal.

REQUIRED TOOL

COUNTERSHAFT OIL SEALPUSHER (P/N 529 036 222)

vmr2012-020-005_a

1. Countershaft oil seal2. Oil seal installer

Shift Shaft Oil SealTo replace the shift shaft oil seal, remove: RH lateral console panel and fuel tank cowl, re-fer to BODY subsection.

Shift plate from shift shaft.The shift shaft oil seal can be removed withoutremoving the gearbox from the vehicle.Use a suitable tube with the proper diameter toinstall the oil seal.If gearbox housing is apart, use following tools forshift shaft oil seal installation.

REQUIRED TOOL

OIL SEAL INSTALLER(GEARBOX) (P/N 529 035 758)

HANDLE (P/N 420 877 650)

NOTICE Oil seal must be installed with seal-ing lip toward gearbox.

Shift Drum Shaft Oil SealTo replace the shift drum shaft oil seal, removethe GBPS (GEARBOX POSITION SENSOR). Seeprocedure in this subsection.Use a suitable tube with the proper diameter toinstall the oil seal.

NOTICE Oil seal must be installed with seal-ing lip toward gearbox.

Output Shaft Oil SealTo replace the output shaft oil seal, proceed as fol-lows:Remove propeller shaft screw from gearbox out-put shaft.Remove rear final drive bolts.Move the rear final drive rearward to dislodge thepropeller shaft from the gearbox output shaft.

Tmr2011-016-015_a

1. Shift shaft oil seal2. Shift drum shaft oil seal3. Output shaft oil seal

Punch a sharp screwdriver through oil seal for re-moval.NOTE: Position screwdriver only in marked areasto avoid damaging the ball bearing underneath oilseal during removal.

192 tmr2013-020


Tmr2011-016-016_a

1. Marked areas for removal2. Output shaft oil seal

Before beginning the installation ensure gearboxis set to PARK position.Apply SUPER LUBE GREASE (P/N 293 550 030) onsealing lips.Apply engine oil on outer diameter of oil seal toavoid damaging it during installation.Place oil seal on output shaft and install it usingthe following tools.

REQUIRED TOOLS AND PARTS

OIL SEAL INSTALLER(P/N 529 036 204)

Flat washer (P/N 250 200 102)

M12 x 1.25 x 35 hexagonal screw

tmr2011-016-020_a

1. Output shaft oil seal2. Oil seal installer3. Flat washer (P/N 250 200 102)4. M12 x 1.25 x 35 hexagonal screw (P/N 207 683 544)5. Apply engine oil on outer diameter of oil seal

GEARBOXGearbox RemovalRemove engine from vehicle. Refer to ENGINEREMOVAL AND INSTALLATION for the proce-dure.Refer to CONTINUOUSLY VARIABLE TRANSMIS-SION (CVT) subsection to remove following parts: CVT cover Drive and driven pulleys CVT air guide.Drain gearbox. Refer to GEARBOX OIL RE-PLACEMENT in PERIODIC MAINTENANCE PRO-CEDURES subsection.Remove ACTUATOR, see procedure in this sub-section.Unscrew the four (4) nuts that attach the gearboxto the engine.

Tmr2011-016-038_a

LH SIDE OF ENGINE1. Nut M8

tmr2013-020 193


Tmr2011-016-039_a

RH SIDE OF ENGINE1. Nut M8

Pull gearbox to separate it from engine.

Gearbox DisassemblyNOTE: During gearbox disassembly, inspect thecondition of each part closely.

Gearbox Left CoverSet gearbox to NEUTRAL position.Unscrew all bolts retaining the gearbox left cover.

Tmr2011-016-043_a

1. 3 screws M6 x 352. 13 screws M6 x 55

Place the center housing on a wood stand, leftcover pointing upwards.Using a big flat screwdriver and a soft hammer tolift the left cover.

Tmr2011-016-044

POSITION FOR SOFT HAMMER

Tmr2011-016-045

POSITION FOR BIG FLAT SCREWDRIVER

Index Lever and Index WasherSet gearbox to NEUTRAL position.Remove screw retaining the index washer to theshift drum.

Tmr2011-016-073_a

1. Screw2. Index washer

194 tmr2013-020


Insert a flat screwdriver in the slot of index lever.Turn screwdriver clockwise and remove indexwasher.

Tmr2011-016-074_a

1. Index lever2. Index washer3. Shift drum

Remove the index lever with washer, step ringand spring.

Tmr2011-016-075_a

1. Washer2. Index lever3. Step ring4. Index spring

Main Shaft and Shift ForksRemove bearing pin, reverse intermediate gearand thrust washers.NOTE: Take care not to lose lower thrust washerduring removal.

Tmr2011-016-046_a

1. Bearing pin2. Reverse intermediate gear3. Needle bearing4. Thrust washers

Remove shift fork shaft.Disengage shift forks from shift drum.

Tmr2011-016-047_a

1. Shift fork shaft2. Shift fork3. Shift drum

Remove main shaft assembly with shift fork.

tmr2013-020 195


Tmr2011-016-048_a

1. Main shaft assembly2. Shift fork

Remove shifting sleeve (HIGH range gear) andshift fork.

vmr2012-020-006_a

1. Shifting sleeve (HIGH range gear)2. Shift fork

When required, remove from main shaft assem-bly: Snap ring (discard) HIGH range gear LOW range gear Needle bearings.

vmr2012-020-007_a

1. Snap ring2. Free pinion (HIGH range gear)3. Free pinion (LOW range gear)4. Needle bearing5. Main shaft assembly

Remove from main shaft assembly: Snap ring (discard) Shifting sleeve (LOW/REVERSE range gear) Snap ring (discard) REVERSE range gear Needle bearing.

vmr2012-020-008_a

1. Snap ring2. Shifting sleeve (LOW/REVERSE range gear)3. Snap ring4. Free pinion (REVERSE range gear)5. Needle bearing6. Main shaft assembly

Gearbox Right CoverRemove ACTUATOR and GBPS (GEARBOX PO-SITION SENSOR), see procedures in this subsec-tion.Unscrew all bolts retaining the gearbox rightcover.

196 tmr2013-020


Tmr2011-016-031_a

1. 5 screws M8 x 552. 2 screws M6 x 853. 2 screws M6 x 554. 8 screws M6 x 35

To remove cover, use 2 big screwdrivers.

Tmr2011-016-032


Tmr2011-016-033


Shift Shaft and Shift DrumWithdraw shift shaft assembly.

Tmr2011-016-071_a

1. Shift shaft assembly

Remove screw retaining the shifting intermediategear.

Tmr2011-016-072_a

1. Screw2. Washer3. Intermediate gear4. Dowel pin

Remove shift fork shaft.Disengage shift forks from shift drum.

tmr2013-020 197


Tmr2011-016-076_a

1. Shift fork shaft2. Shift fork3. Shift drum

Remove shift drum and thrust washer.

Tmr2011-016-077_a

1. Shift drum2. Thrust washer

Output Shaft and 4X4 Coupling MechanismRemove output shaft from center housing andwithdraw 4X4 coupling sleeve.

NOTICE Use a soft hammer to remove outputshaft.

Tmr2011-016-034_a

1. Output shaft2. 4X4 coupling sleeve3. Soft hammer

Remove set screw, coupling fork shaft and cou-pling fork from right cover.

Tmr2011-016-035_a

1. Set screw2. Coupling fork shaft3. Coupling fork

CountershaftUse a soft hammer to push out countershaft fromgearbox CVT side.Remove distance sleeve and O-ring.

198 tmr2013-020


Tmr2011-016-042_a

1. Countershaft2. Distance sleeve3. O-ring

Gearbox BearingsIf necessary heat housing up to 100C (212F) be-fore removing ball bearings.

WARNINGClean oil, outside and inside, from housingbefore heating.

NOTICE Always support gearbox housingsproperly when ball bearings are removed.Housing damages may occur if this procedureis not performed correctly.

To remove ball bearings of countershaft (rightcover) and main shaft (left cover) use followingtool.

REQUIRED TOOL

BLIND HOLE BEARINGPULLER SET (P/N 529 036 117)

Remove screw securing the countershaft bearingin the left cover.For ball bearings of countershaft (left cover) andmain shaft (center housing) push with a suitablepuller from outside in.

Tmr2011-016-052_a

1. Ball bearing countershaft2. Right cover

Tmr2011-016-053_a

1. Screw2. Ball bearing countershaft3. Ball bearing main shaft4. Left cover

Tmr2011-016-054_a

1. Ball bearing main shaft2. Center housing

tmr2013-020 199


Gearbox InspectionAlways verify for the following when inspectinggearbox components: Gear teeth damage Worn or scoured bearing surfaces Rounded engagement dogs and slots Worn shift fork engagement groove Worn splines on shafts and shifting sleeves.

BearingsCheck if ball bearings turn freely and smoothly.Check all bearings, bearing points, tooth flanksand taper grooves.

Free PinionsNOTE: Always replace snap rings and use specialpliers to install them.Check free pinions for wear.

vmr2006-022-080_a

TYPICAL1. Micrometer2. Free pinion

DIAMETER FREE PINION

NEW 29.000mm to 29.013mm(1.1417 in to 1.1422 in)

SERVICE LIMIT 29.015mm (1.1423 in)

Shifting SleevesCheck shifting sleeves for worn inner splines androunded or damaged engagement dogs.

vmr2012-020-009_a

TYPICAL1. Inner splines2. Engagement dogs

Measure the width of shift fork engagementgroove.

Tmr2013-020-001_a

TYPICAL1. Shifting sleeveA. Width of shift fork engagement groove

WIDTH OF SHIFT FORK ENGAGEMENT GROOVE

NEW 5.30mm to 5.40mm(.209 in to .213 in)

SERVICE LIMIT 5.50mm (.217 in)

ShaftsCheck bearing pin of reverse intermediate gear forwear.

200 tmr2013-020


Tmr2011-016-057_a

1. Bearing pinA. Outer diameter

BEARING PIN OUTER DIAMETER



Check countershaft bearing journals for wear.

Tmr2011-016-058_a

A. MAG sideB. Bearing journal CVT side

COUNTERSHAFT BEARING JOURNALS

MAG SIDE



CVT SIDE



Check main shaft for wear.

Tmr2011-016-059_b

A. Bearing journal MAG sideB. Free pinion bearingC. Bearing journal CVT side

MAIN SHAFT

FREE PINION BEARING



BEARING JOURNAL CVT/MAG SIDE



Shift ShaftCheck shift shaft for worn splines and gears.Check shift shaft spring for damages.

Shift Drum

NOTICE Do not disassemble shift drum.

Check if shifting gates move easily on shift drumsplines and check condition of springs.Check shift drum tracks for scouring or heavywear, like rounded engagement slots.

tmr2013-020 201


Tmr2011-016-080_a

1. Track for the low/reverse range gear shift fork2. Track for the high range gear shift fork3. Springs

Shift ForksCheck both shift forks for visible damage, wear orbent shift fork claws.Check engagement rollers for wear and smoothmovement.Measure the shift fork claw thickness.

vmr2006-022-075_a

1. MicrometerA. Shift fork claw thickness

SHIFT FORK CLAW THICKNESS



Shift Fork ShaftCheck shift fork shaft for visible damage or wear.Check if shift fork shaft is straight.

Index Lever and Parking LeverIndex lever with roller must move freely.Check parking lever for cracks or other damages.

Output ShaftCheck output shaft and its gear for cracks, bend,pitting or other visible damages.Check output shaft splines for wear or other dam-ages.Check if the output shaft bearings turn freely andsmoothly.Replace oil seal if brittle, hard or damaged.

4X4 Coupling SleeveCheck splines of coupling sleeve for wear or otherdamages.

vmr2006-022-030_a

1. Inspect splines

Measure the coupling sleeve groove width.

vmr2006-022-031_a

A. Groove width

COUPLING SLEEVE GROOVE WIDTH



Coupling ForkCheck coupling fork for visible damage, wear orbent coupling fork claws.Check coupling fork claw thickness.

202 tmr2013-020


vmr2006-022-032_a

1. Coupling fork2. Micrometer

COUPLING FORK CLAW THICKNESS



Gearbox AssemblyThe assembly of gearbox is essentially the reverseof disassembly procedure. However, pay atten-tion to the following details.

Gearbox BearingsUnless otherwise instructed, never use hammerto install ball bearings. Use press machine only.If necessary heat housings up to 100C (212F)before installing ball bearings.

WARNINGClean oil, outside and inside, from housingbefore heating.

Place new bearing in freezer for 10 minutes be-fore installation.Use a suitable installer for installing ball bearingsof countershaft and main shaft.NOTE: Place gearbox housings on a wood standbefore installing ball bearings.Install new oil seals with the proper installer (referto OIL SEALS in this subsection).

Main Shaft and Shift ForksInstall NEW snap rings.NOTE: Ensure snap rings are installed in thegrooves properly.Install free pinion (REVERSE range gear) and shift-ing sleeve (LOW/REVERSE range gear) properly.

vmr2012-020-011_a

1. Main shaft2. Free pinion (REVERSE range gear)3. Snap ring4. Shifting sleeve (LOW/REVERSE range gear)5. Shifting dogs (REVERSE range gear)

Collars of free pinion (LOW range gear) and freepinion (HIGH range gear) must point together.

Tmr2013-020-002_a

1. Free pinion (LOW range gear), 44 T2. Collar3. Free pinion (HIGH range gear), 36 T4. Collar

Place shifting sleeve (HIGH range gear) with shiftfork in the center of on main shaft bearing in cen-ter housing.

tmr2013-020 203


vmr2012-020-006_a

1. Shifting sleeve (HIGH range gear)2. Shift fork

Carefully fit main shaft assembly with shift fork(LOW/REVERSE range gear) into inner splines ofshifting sleeve (HIGH range gear).Install reverse intermediate gear.

Tmr2011-016-046_a

1. Bearing pin2. Reverse intermediate gear3. Needle bearing4. Thrust washers

Finally engage shift forks in shift drum and installshift fork shaft.NOTE: Run all gears as a final function check be-fore installing left housing.

Index Lever and Index WasherFit step ring into index lever.

Tmr2011-016-075_b

1. Index spring2. Step ring3. Index lever4. Washer5. Screw

Install index washer on shift drum.Insert a flat screwdriver in the slot of the indexlever, turn screwdriver clockwise and engagelever in index washer in neutral position as perfollowing illustration.

Tmr2011-016-086_a

1. Index lever2. Index washer3. Neutral position4. High range gear position5. Low range gear position6. Parking position7. Reverse range gear position

Output Shaft and 4X4 Coupling MechanismInstall coupling sleeve onto the output shaft.Place the output shaft with oil seal and couplingsleeve into the center housing.NOTE: If same oil seal is installed, turn oil seal 90offset to its original position to avoid leakage athousing mating surface.

204 tmr2013-020


Install coupling fork, coupling fork shaft and setscrew in right cover before applying sealant to themating surface.

Tmr2011-016-037_a

1. Coupling fork2. Coupling fork shaft3. Set screw

Shift Shaft and Shift DrumInstall shift drum and shift shaft.Install shifting intermediate gear. Align its markswith the marks on shift drum gear and shift shaft.

Tmr2011-016-087_a

1. Shift shaft assembly2. Shifting intermediate gear3. Shift drum gear4. Marks

Engage both shift fork pins in their correspondinggroove on the shift drum.Install shift fork shaft.NOTE: Turn gears to validate proper operation.

Sealing Compound ApplicationNOTE: Unless otherwise specify, the procedureto apply the sealant is the same for right or leftcover.Clean all metal components in a solvent.

Gearbox housing mating surfaces are bestcleaned using a combination of LOCTITE CHISEL(GASKET REMOVER) (P/N 413 708 500) and a brassbrush. Brush a first pass in one direction thenmake the final brushing perpendicularly (90) tothe first pass cross (hatch).

NOTICE Do not wipe with rags. Use a newclean hand towel only.

IMPORTANT: When beginning the application ofthe gear housing sealant, the assembly and thefirst torquing should be done within 10 minutes.It is suggested to have all you need on hand tosave time.Use LOCTITE 5910 (P/N 293 800 081) on mating sur-faces.Use a plexiglass plate and apply some sealanton it. Use a soft rubber roller (50mm - 75mm(2 in - 3 in)), available in arts products suppliers forprinting, and roll the sealant to get a thin uniformcoat on the plate (spread as necessary). Whenready, apply the sealant on gear housing matingsurfaces.

Do not apply in excess as it will spread out insidegear housing.NOTE: It is recommended to apply this specificsealant as described here to get a uniform appli-cation without lumps. If you do not use the rollermethod, you may use your finger to uniformly dis-tribute the sealant (using a finger will not affectthe adhesion).

Left CoverApply sealing compound on mating surfaces ofcentral housing. Refer to SEALING COMPOUNDAPPLICATION.

tmr2013-020 205


At installation of left cover, engage parking locklever slot onto index washer pin.

Tmr2011-016-065_a

1. Left cover2. Parking lock lever slot3. Index washer pin

Install all screws on left cover and tighten them asper following sequence.

Tmr2011-016-043_b

M6 SCREWS - LEFT COVER

Tightening torque 10Nm 1Nm(89 lbfin 9 lbfin)

Install O-ring including distance sleeve on counter-shaft CVT side.

NOTICE Place O-ring including distancesleeve right away. Chamfered bore of distancesleeve has to face the gearbox.

Tmr2011-016-067_a

COUNTERSHAFT END CVT SIDE1. O-ring2. Distance sleeve3. Countershaft end CVT side

Right CoverApply sealing compound on mating surfaces ofcentral housing. Refer to SEALING COMPOUNDAPPLICATION.To install the right cover align the coupling forkwith the groove in the coupling sleeve.Install all screws on right cover and tighten themas per following sequence.

Tmr2011-016-031_b

SCREWS - RIGHT COVER

Tightening torque - M6 10Nm 1Nm(89 lbfin 9 lbfin)

Tightening torque - M8 25Nm 3Nm(18 lbfft 2 lbfft)

Install the actuator, refer to ACTUATOR.

Gearbox InstallationFor installation reverse the removal procedure.Pay attention to following.

206 tmr2013-020


Before gearbox installation check O-ring in bearingcover if brittle, hard or damaged. Replace if nec-essary.

Tmr2011-016-040_a

1. Bearing cover2. O-ring

After installation refill gearbox oil, refer to PERI-ODIC MAINTENANCE PROCEDURES.

tmr2013-020 207

Caja de Cambios Outlander

Documents

Transcript of Caja de Cambios Outlander